Removing the engine Note: Cover the fenders with a protective cloth to prevent damage to the paintwork. To avoid damaging the electrical wiring, disconnect it carefully by grasping the connector. Label all wiring and hoses to avoid...
Valve clearance adjustment Note: The valves should only be adjusted when the temperature of the cylinder head is below 38°C. After adjustment, loosen the crankshaft pulley bolt, then retighten it to 20 Nm (2.0 kgf/m) and tighten by 90°. 1....
Crankshaft pulley — replacement 1. Remove oil from pulleys, crankshaft, bolt and washer. Perform cleaning and lubrication as shown in the figure. 1. pulley bolt; 2. crankshaft pulley; 3. timing belt drive pulley; 4. crankshaft; 5. timing belt guide...
Timing Belt — Design Description 1. WASHER, Replace if damaged or failing. 2. 6x1.0 mm, 9.8 Nm (1.0 kgf/m) 3. CYLINDER HEAD COVER, when installing see below . 4. CYLINDER HEAD COVER GASKET, Replace if leaking, damaged or failed. Apply sealant to the...
Timing belt — check 1. Disconnect the breather hose, then remove the air cleaner cover. 2. Remove the cylinder head cover. When installing the cylinder head cover, see p. « Installation ». 3. Remove the top cover. 4. Check for cracks in...
Timing belt — tension adjustment Note: Adjust the timing belt tension on a cold engine. The tensioner is spring loaded and tensions the belt automatically after the next adjustment is completed. Rotate the crankshaft counterclockwise as viewed from the...
Timing belt — removal Note: Before removing the belt, turn the crankshaft pulley so that the piston of cylinder No. 1 is at top dead center (TDC). Check the water pump before installing the timing belt. 1. Remove the mudguard. 2. Remove air...
Timing Belt — Installation The timing belt is installed in the reverse order of removal; only the key points of this procedure are given below. 1. Rotate the timing belt drive pulley until the #1 cylinder piston is at top dead center. Align the...
Exhaust pipe and muffler replacement 1. 6x1.0 mm, 9.8 Nm (1.0 kgf/m) 2. HEAT SHIELD 3. EXHAUST PIPE B 4. MUFFLER 5. GASKET. Replace. 6. SELF-LOCKING NUT, 10x1.25 mm, 54 Nm (5.5 kgf/m). Replace. 7. EXHAUST GAS TEMPERATURE SENSOR (EGT) (except for KU models)...
Cylinder head — design description Note: To prevent damage to the cylinder head, wait until the engine coolant temperature has dropped to 38°C before removing it. When handling the metal gasket, do not bend it or damage the contact surface. Install new...
Cylinder head — removal This procedure does not require removal of the engine. Note: Cover the fenders with a protective cloth to prevent damage to the paintwork. To avoid damaging the electrical wiring, disconnect it carefully by grasping the...
Rocker arms — removal 1. Loosen the adjusting screws. 2. Turn off bolts of arms of a camshaft, then remove yokes in gathering. Note: To avoid damaging the valves or rocker assemblies, loosen the camshaft bracket bolts in a criss-cross...
Rocker arms — disassembly and assembly 1. Letter «IN» embossed on the valve rocker 2. INTAKE VALVE ROCKER B (4 seats) 3. INTAKE ROCKER AXLE 4. INLET VALVE ROCKER A (4 seats) 5. Letter «A» embossed on the valve rocker 6. SPRING (4 seats) 7. ROCKER BUSHING (4...
Rocker Arms and Axles — Checking Clearances Measure the rocker arms for both the intake and exhaust valves. 1. Measure the axle diameter at the location of the first rocker arm. 2. Set the inside gauge to zero on the axle diameter. 3. Measure the inner diameter...
Camshaft — check Note: Do not turn the camshaft while checking. Remove rocker arms and valve rocker shafts. 1. Put the camshaft and brackets on the cylinder head and tighten the bolts to the required torque. 2. Move the camshaft towards...
Valves, springs and seals — removal Note: Mark the valves and valve springs as they are removed so that all components can be reinstalled in their original position. 1. Before installing the valve spring compressor, lightly tap the valve disc with a...
Valve guides — check Valve travel Measure the clearance between the valve stem and valve guide with a dial gauge by jiggling the valve in the valve guide. If the measurement exceeds the allowable limit, repeat the measurement with a new...
Cylinder Head — Warping Check Note: If the oil clearance between the camshaft and brackets ( see above ) more than allowed, the cylinder head must not be reground. If the oil clearance between the camshaft and brackets is within tolerance, check the...
Valve Seats — Rebuild 1. Restore the valve seats in the cylinder head with a cutter. Note: If the guide bushings are worn ( see above ), replace them ( see below ) before machining valve seats. 2. Carefully machine the 45°seat, removing only...
Valve guides — replacement Note: For best results, heat the cylinder head to 150°C before removing or installing guides. Some guides may require a pneumatic hammer to remove. 1. Knock out the valve guide from the bottom of the cylinder head. 2....
Valves, Springs and Seats — Installation 1. Insert the valves into the guide bushings; coat the valve stems with engine oil before installation. Note: Make sure the valves move freely in the guide. 2. Install the spring seats in the cylinder head. 3. Install...
Camshaft, rocker arms, oil seal and camshaft pulley Installation Note: When tightening the rocker arm mounting bolts, make sure all rocker arms are aligned with the valves. Before installation, loosen the valve locknuts and unscrew the adjusting screws. To prevent the...
Cylinder head — installation Installation of a head of cylinders is carried out in an order, the return to removal. Note: Always put a new gasket under the cylinder head. The contact surfaces of the head and cylinder block must be clean. Label «UP»...
Cylinder block and piston group Note: Before installing the right cover and oil pump housing, apply sealant to their contact surfaces. Use sealant P/N 08C70 - K0234M, 08C70 - K0334M or 08C70 - X0331S. Lubricate all internal parts with engine oil when...
Flywheel and Drive Disc — Replacement Manual Transmission (ITUC) Remove the six flywheel bolts, then separate the flywheel from the crankshaft flange. After installation, tighten the bolts crosswise. 1. RING HOLDER, 07LAB-PV00100 2. CYLINDER BLOCK 3. 12x1.0...
Piston and connecting rod — design description Note: New connecting rod bearings must be matched to the identification marks on the connecting rod and crankshaft ( see below ). Lubricate all internal parts with engine oil when assembling. 1. PISTON INSTALLATION...
Connecting rod and crankshaft — end play Axial play of the connecting rod: Standard (new): 0.15-0.30mm Redistribution: 0.40 mm If the play is more than acceptable, install a new connecting rod. If play is still significant, replace crankshaft ( see below )....
Main bearings — clearance 1. To check the oil clearance between the main bearing and journal, remove the main bearing caps and bushings. 2. Clean the main journals and bearings with a clean cloth. 3. Lay a length of gauged Plastigage wire across...
Main bearings — selection The location of the markings of the main journals (numbers) Bearing marking The color marking is located on the edge of the bearing. Location of the crankshaft marking on the cylinder block Note: If the marking cannot...
Connecting Rod Bearings — Clearance 1. Remove the connecting rod cap and bearing shell. 2. Wipe the connecting rod journal on the crankshaft and the bearing shell with a clean cloth. 3. Lay a length of gauged Plastigage wire across the crankpins. 4....
Pistons and crankshaft — removal 1. Remove the oil pan assembly. 2. Remove the right cover. 3. Remove the coarse oil filter. 4. Remove the oil pump. 5. Turn off bolts. To avoid warping, loosen the bolts sequentially 1/3 turn at a time; repeat the...
Crankshaft — check Clean the oil passages on the crankshaft with pipe cleaner and a suitable brush. Check keyway and thread. Reconciliation Measure the runout of all main journals and make sure the crankshaft is not bent. The difference...
Pistons — check 1. Check pistons for deformation or cracks. Note: If the cylinder has been bored, an oversized piston should be installed. 2. Measure the piston diameter at point A from the bottom of the skirt. Piston diameter:...
Cylinder Block — Inspection and Honing 1. Measure wear and taper in the X and Y directions at three points in each cylinder as shown. Cylinder diameter: Standard (new): 75.00-75.02mm Limit: 75.07mm Increased repair size: at 0.25: 75.25-75.27 mm at 0.50:...
Piston pins — removal Note: Remove piston pins with a special tool kit (P/N 07PAF-0010000). Use the correct numbered guide bushing. 1. Assemble the special tool as shown in the figure. 2. Install the piston on the special tool and press out...
Connecting rods — selection Depending on the diameter of the big head, all connecting rods are divided into four groups according to the tolerance limit (0 to +0.024 mm in 0.006 mm increments). This limit is indicated by a stamped figure (1, 2, 3...
Piston pins — installation and inspection Installation Note: Install the piston pins using a special tool kit (P/N 07PAF-0010000) and hydraulic press. Use the correct numbered guide bushing. 1. The arrow should point towards the engine timing belt and the oil...
Piston rings — check and replace Gap in the castle 1. Push a new ring with a piston into the cylinder to a depth of 15-20 mm from the bottom. 2. Measure the clearance in the piston ring lock with a feeler gauge: If the clearance is too small, check if...
Crankshaft oil seal — installation The oil seal surface on the cylinder block must be dry. Apply a thin layer of oil to the crankshaft and to the lip of the oil seal. 1. Press the crankshaft oil seal into the right cover. Note: Press in the crankshaft...
Pistons — installation Apply a light coat of engine oil to the ring grooves and cylinder walls before installing the pistons. 1. If the crankshaft is already installed: Set the crankshaft to BDC for each cylinder. Remove the caps from the...
Crankshaft — Installation Before installing the crankshaft, apply engine oil to the main and connecting rod bearings. 1. Insert the thrust washers on the neck No. 4 of the cylinder block. 2. Insert loose leaves of bearings into a bed of the...
Oil pan — installation Models for Europe, Australia and South Africa: Note: Use sealant P/N 08C70-K0234M, 08C70-K0334M, or 08C70-X0331S. Make sure contact surfaces are clean and dry before applying sealant. Apply sealant evenly, distributing...